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The vertical Boom-type Roadheader designMechanical design is in the process of product design and an important part of the main links, it is followed in programme design after the design work. The vertical Boom-type roadheader (the roadheader) to the overall design of the merits of complete machine play a decisive role, and the decision of the assembly, the system, coordination between the various components of the unity and match, to obtain the high-end performance and overall better economic efficiency technology.Roadheader design, including the following:1) According to design project description choice type and various cellular construction pattern2) Decides the complete machine the main technical performance parameter, Including size parameter, heavy parameter, the parameter of movement and the technical economy refer parameter,3) According to system design performance requirement, definite complete machine system composition and between them match as well as each part main technical senate parameter,4) The necessary whole, and the mapping of transmission, hydraulic, electronic control systems, and other plans.1 the selected models and various components and structural type, drive, and the overall layout of the reasonableIn determining the content, first task should be designed to meet the contents, especially the users of the main demands of the investigation, the two sides exchanged views repeatedly, to satisfy both users (or superior) conditions, can better meet the product development of the overall plan.1) the selected modelsAccording to roadheader use, for the coal mine tunnel boring or used for other sectors of the works, roadheader working conditions for cutting coal roadway or semi-Coal Lane, the compressive strength of coal and rock one-way (or the value of platts coefficient f) and the rock abrasion factor. At the same time the control line should be superscript MT138 1995 cantilevered Roadheader types and parameters, according to cutting coal and rock the biggest one-way compressive strength, the type of selected models.2) the structure of the various components, the way the driver identifiedRoadheader by cutting general agencies, shipping agencies, walking, hydraulic system, electronic control systems and auxiliary devices (such as dust removal devices, security devices, remote monitoring devices) and other components.a. Cutting agencies. Cutting the drive from AC motor-driven, in the transmission system located in the general profile coupling with no mechanical overload protection device, the two planets reducer driven spindle front of the cutting head.Some sections of the working bodies boring machine has cut chain, disc-milling and cutting-such as cantilever. Cantilever due to the cutting-boring machine body flexible, relatively small, can cut a variety of shapes and sections of the roadway, and to achieve selective cutting, but cutting good effect, a higher rate of boring, so now used mainly cantilever Cutting-and has become boring machine working body of a basic pattern.By cutting head of the layout, is divided into horizontal and vertical axis of the two. The line-cutting head of the advantages are: Transmission convenient, compact and can be cut to any shape of the profile, easy access to the formation of a cross-section and is conducive to expansion in the use of cantilever, or ditch digging, in Waterloo. Cutting head the shape of a cylindrical, cone and the cone and cylindrical, as the latter two cutting head to drilling, and the cutting surface than the formation, use it more. This is the work of the shortcomings: As the longitudinal axis of cutting head in the horizontal swing at the cutting reaction force is not passed machine centres, with cantilevered form of torque to boring machine have a greater vibration, stability is poor. Therefore, the coal roadway excavation, the need to increase the body weight or support the installation of auxiliary equipment. At present, such a boring machine in some sections of the use of more boring machine.b. Run institutions. Walking agencies tracked the general pattern, crawler-run institutions apply to the floor is uneven or soft conditions, no road track laying. Traction with large capacity, good mobility, reliability, flexibility and mobility on the floor adaptability of the advantages of good. But its complex structure, components and wear more serious. At present cross-section of the boring machine is usually used crawler-run institutions.Walking agencies tracked the general pattern, the two tracked separately by the respective power to drive, to achieve in situ. Caterpillar is the driving force of two motors and hydraulic motors, motor driver is generally set up a walking speed, hydraulic motor-driven large low-speed torque motor can be driven directly tracked sprocket, or used in the hydraulic motor speed Reducer led the drive sprocket track, it can achieve Promise governor.Tracked structure of a sliding and rolling two, when the speed machine to mobilize 10 m / min in the light Roadheader, should adopt the structure of sliding when the mobilization of speed machines 10 m / min of heavy, severe Roadheader should be used Rolling structural type.c. The hydraulic system. Hydraulic systems use of open-way valve system more centralized control (direct or remote control manipulation) way. Domestic and foreign use of the past, gear pumps, hydraulic system in recent years Roadheader used piston pump have increased the trend.d. Electronic control system. Electronic control systems, including some power, control and inspection of the part. Electronic control system must be in accordance with the requirements of coal mine explosion-proof design, manufacture, testing, GB3836-2000 must meet the standards of the relevant provisions and requirements. In order to improve operations at the Roadheader in the security, operational flexibility and mechanical transmission part of the fault diagnosis and monitoring functions, from the practical point of view, the installation of the necessary machines from a remote control device, monitoring pressure, temperature, level and key parts the fault diagnosis device.3) LayoutGeneral layout of the contents include the following: (1) Identify the components in complete machine said the location, shape and size of the request; (2) To identify the parts, components and the connections between complete machine; (3) estimates complete machine weight and the weight of all components requested; (4) layout of the manipulation of institutions, the drivers seat; (5) examination of moving parts of the movement space, rule out the possibility of interference in the campaign. 4) specific requirements Boring machine in the general layout, the need to pay attention to the following questions: (1) institutions into the reducer reducer, as far as possible to coax axis; (2) cantilever and spade-suited to the size of relations, not only conducive to loading, to avoid cutting the first shovel cutting board; (3) the level of cantilever and vertical position can swing the center coincidence, can not overlap. From the increased stability of the machine, these are highly swing should be reduced. In the cantilever is not guaranteed to interfere with other agencies under the conditions of swing centres are located should try to rely on, but must ensure that the machines in the centre plane of vertical symmetry; (4) Caozong Tai position should be appropriate, should ensure that drivers easy manipulation, and effort. Instruments showed that the location devices for drivers to observe, not scattered normal operation of the drivers attention. 5 ) types and power transmission components choice transmission patterns and components should follow the principle of choice (1) the advanced nature of technology: machines to improve performance, increase productivity; (2) economic rationality: drive system as simple as possible, fewer components and easy processing, low price, easy maintenance, long life; (3) reliability of the work: the transmission system reliability performance for the life of components, as well as component quality requirements; (4) adaptation: the drive system components should be adapted to load, working conditions and environmental conditions of the request. Agencies to the transmission system requirements and the choice of transmission patterns .Boring machine cutting, loading, transport, walking and other institutions generally are respectively transmission, all parts of the state and subject to different working conditions, thus driving patterns have different requirements. （1) institutions require a greater short-term Guozainengli, motor oil is very sensitive to the impact load, the loading capacity of low-impact cutting head for normal functioning. Therefore, the boring machine working body should adopt the motor-driven mechanical transmission type. Should make use of small size, power, a strong capacity for electric motors, and equipped with reliable electrical protection device. According to the compact body of work features, usually work in the reducer cantilever, an integral part of a cantilever. Cutting the first governor general way with a round peg for the method of transmission organizations to simple. (2) rake with institutions transmission device is characterized by: reducer be installed in the limited size of the lower part of the shovel plate, thus design a smaller space, poor working conditions. Reducer often soaked in muddy coal and rock in the cards when the material easy to overload. Trailing equipment, transportation agencies the use of motor oil transmission gear, as small size, light weight, will enable the two separate drive, thus simplifying transmission device, for the spade under the board layout, designed for good results sealed mechanical seal or reducer And shovel plate separation, while achieving automatic overload protection. 2 determination complete machine main technology senate parameter Mechanical Roadheader complete machine main technical parameter including size senate parameter (length width highly); weight parameter, parameter of movement and dynamic parameter.1 ) size parametersComplete machine length, width of the size directly related to its turning radius, Recommended light-length 7.5 m, medium-length 8.5 m, heavy machine l0m, the corresponding width were 1.6 m, 2.5 m, 3 m. The complete machine relates its tendency, the static stability highly directly, the adaptation scope and passes quality, therefore lower better. The current development trend of Chinese and foreign models is the dwarf models, medium and heavy-high 1.6 2 m, special light, light machine the height of 1.4 1.6 m. Roadheader to dig the biggest section of roadway, the minimum height and width should be designed to meet the requirements of the mission. Undercover depth of 250 400 mm, ground clearance C = B/13 +84 (mm), B for the two track distance). Middle-long conveyor entrance to the expected high degree of the best 400 mm, length of track ground with the center distance L B ratio for L / B 1.6.2 ) weight parametersThe complete machine dead weight is the mechanical roadheader - an important parameter, the engine weight too is light, the work stability drops, when swinging cutting can occur fishtails the phenomenon, the cutting efficiency drops, truncation tooth rate of wear increase; Heavy-weight, poor mobility, flexibility to decline. The self-respect as it may be w = (t) estimates, in the N-type body for cutting power, kW; V for the cutting head on average cutting speed, m / s; can also be Roadheader with reference to the existing analog method to determine , machine-(t) and cutting power (kW) ratio of 0.25 to 0.4. For general coal, rock bottom, the allowable value 0.14 MPa; muddy for the water to soften the shale bottom, 0.05 MPa.3) movement parametersCutting the movement parameters: cutting head of the average cutting speed V: on the one-way coal and rock compressive strength of 40 MPa, V = 3 3.5m / s; 60MPa, V = 2 2.5m / s, 60MPa. V = l 2m / s. But eventually cutting speed by cutting technology to determine.4) technical and economic indicatorsQ = (m3/min), in the sx-cutting head for the vertical cross sectional area, m2: Vn for the cutting head of cutting swing speed, m / min.Roadheader designed life, in the international advanced products up to 3 to 5 years, during which the need of major repair or wells, the general domestic product for 1 to 2 years.3 in accordance with design requirements. Determine the parameters of the main components and their relationship between the connector1) cutting agencies and technical parameters of the established link between(1) Cutting-agency technical parameters of cutting the head with the general pick for the double-headed or three spiral layout. Cutting head speed n = 20 65r/min, a sharp pick cutting the average speed V = 1.5 2.5m / s, cutting swing speed Vn = 0.8 l0m / s. Cut-off line from t = 20 50mm, (when cutting coal from the value of all-time for small value). Average single-pole/double-throw force should reach: f4 grade coal and rock F 2500 N, f6 grade coal and rock F 5000 N, f8 grade coal and rock F 12000 N, pick the best angle for the installation of 45 48 .(2) Cutting the link .Cutting agencies cantilever Chaxing-installed in front of the fixed-Chaxing rotary table, the turret to the rack. According to cutting agencies in the course of operating the force and torque, the application of MT475-1996 cantilevered Roadheader rotary bearing type, the basic parameters and technical requirements selected rotary bearing the structural type, determined by calculating slewing ring size specifications. If the user does not require a cantilever stretching structure, is generally not recommended.2) shipping agencies determine the parameters (1) Loading mechanism Loading bodies and Middle conveyor used linkage or single-action mode, loading the bodies rake claws speed is generally 25 48 r / min. Star Ferrys speed can be slightly higher than some. Using direct-drive hydraulic motors, the maximum output torque rated torque for calculating the value of 1.5 times. Shovel coal-general of the tilt angle to 21 25 , it should be the width of track, spacious than the 0.6 1.2 m, declining position should not be less than the minimum depth of undercover maximum height should be increased to 350 400 mm. (2) Intermediate conveyor Middle conveyor chain may be single or double-stranded chain structure of the ring chain, chain-speed should not exceed 0.92 m / s, using the U.S. chain of universal sleeve roller chain single chain, the chain speed should not exceed 2.5 m / s, generally from 1.6 2 m in order to meet the changing demands a high degree of unloading, the tail should be set up multi-stage hydraulic cylinders to achieve take-off and landing movements, raising the minimum height for the hopper and a high degree of around 300 mm. If the tail need to swing around, the United States must adopt a universal sleeve roller chain, to set the location of the side-effect hydraulic cylinder to achieve the tail swing around 45 , to expand the width of unloading. 3) running track and identify the technical parameters of connectivity between a)walking track drivers and transmission patterns have the following two ways, the overall design and layout determined at the time one of them. (1) Drive a motor-driven than reducer (i 250) led initiative sprocket. Can only establish a walking speed of 5 7.5 m / min. (2) The speed of a hydraulic motor torque direct drive or take the initiative sprocket of a slowdown in high-speed motor driven me a sprocket can take the initiative to achieve rapid mobilization and the need to slow operations, walking speed of 0 10 m / min of no - Speed. b) tracked the transmission link between Structure has two sliding and rolling, sliding simple structure, the resistance of larger, the special light, light and medium-sized roadheader recommend sliding structured. Rolling resistance smaller operation, crawler-crawler at the bottom and wear small chain of contacts. Heavy and severe roadheader recommend using this structure type. Track-installed at the bottom of the supporting wheels, each bearing capacity should be not less than 50 percent of weight, distance is generally tracked the plate pitch 1.5 times. 4) the hydraulic system of technical parameters establishedHydraulic system of technical parameters should be determined in the hydraulic design calculations. The pressure should not be rated higher than the 20 25 MPa. A hydraulic motor in the system should be set up power transmission cooler, the system in the optional round series at the pump, rated pressure announced that the following 20 MPa. Selection of pumps and motors of the Anyu should be around 1.5. Each loop system in the pressure relief valve is set for the rated pressure of 1.8 to 2.2 times suitable.5) electronic control system identified the main technical parametersElectronic control system of power supply voltage should be roadheader models to determine the size of pressure levels, special light, light machine should be elected 660 V, medium and heavy aircraft should be elected 660 V/1140V. Some momentum in the electrical circuit components, the power supply should meet the range of 70% to 115% of the requests. 4 the overall calculation of the necessary plans and systems Such as in roadheader design and overall layout is complete with two of the main components of each system and the main structure, the basic technical parameters have been determined, theComplete machine should carry out the necessary calculations and the overall system, and other plans. (1) Cutting agencies roadheader static and dynamic stability of the calculation. (2) Transmission and hydraulic components of the electronic control system of power calculation. (3) Hydraulic system heat balance calculations. (4) Drawing transmission, hydraulic, electronic control system plans. (5) Drawing cutting sections of roadway. 5 Conclusion Roadheader design is roadheader design projects in the technical design of the components. It is the key to the design of the overall performance parameters of reasonable choices, the assembly of each system and optimize the design standards, in particular, cutting the cutting technology is particularly important. 悬臂纵轴式掘进机的总体设计总体设计是机械产品设计过程中的重要内容和主要环节，它是在方案设计之后紧接着进行的设计工作。悬臂纵轴式掘进机(以下简称掘进机)的总体设计对整机性能的优劣起着决定性的作用，并决定了各总成、系统、各部件之间的协调性，统一性和匹配关系，从而获得总体的高端 性能和较好的技术经济效益。 掘进机的总体设计，主要包括以下内容： 1）据设计任务书选择机型及各部件结构型式 2）定整机的主要技术性能参数，包括尺寸参数、重量参数、运动参数和技术经济指标 3）按照总体设计的性能要求，确定整机系统的组成 及它们之间的匹配性以及各个部件的主要技术参数 4）进行必要的总体计算，并绘制传动、液压、电控系统图等。 1选定该机型和各个部件及其结构型式、驱动方式、并进行总体的合理布置该项内容在确定前，首先应满足设计任务书的内容，特别是用户提出的主要要求经过调研，双方反复交换意见，达到既能满足用户(或上级)条件，又能较好的符合本企业产品发展的总体规划。 1）机型的选定 根据掘进机的用途，是用于煤矿井下巷道的掘进还是用于其他行业的工程作业，掘进机的工作条件是用于截割煤巷还是半煤岩巷，煤岩的单向抗压强度(或普氏系数f值)及岩石的磨蚀系数。同时应对照行标MT1381995悬臂式掘进机的型式与参数，按其截割煤岩的最大单向抗压强度，选定机型的类别。 2）各部件结构型式、驱动方式的确定 掘进机一般由截割机构、装运机构、行走机构、液压系统、电控系统及辅助装置(如除尘装置、安全装置、遥控 监测装置)等组成。 a截割机构。截割机构的驱动方式由交流电动机驱动，在传动系统中一般设齿形联轴节，不设机械式过载保护装置，经两级行星减速器带动主轴前端的截割头。部分断面掘进机的工作机构有截链式、圆盘铣削式和悬臂截割式等。因悬臂截割式掘进机机体灵活、体积较小，可截出各种形状和断面的巷道，并能实现选择性截割，而且截割效果好，掘进速度较高；所以，现在主要采用悬臂截割式，并已成为当前掘进机工作机构的一种基本型式。按截割头的布置方式，分为纵轴和横轴式两种。纵轴式截割头的优点是：传动方便、结构紧凑，能截出任意形状的断面，易于获得较为平整的断面，有利于采用内伸缩悬臂，可挖柱窝或水沟。截割头的形状有圆柱形、圆锥形和圆锥加圆柱形，由于后两种截割头利于钻进，并使截割表面较平整，故使用较多。这种工作机构的缺点是：由于纵轴式截割头在横向摆动截割时的反作用力不通过机器中心，与悬臂形成的力矩使掘进机产生较大的振动，故稳定性较差。因此，在煤巷掘进时，需加大机身重量或装设辅助支撑装置。目前，这种掘进机在部分断面掘进机中使用较多。b行走机构。行走机构一般采用履带型式，履带式行走机构适用于底板不平或松软的条件，不需修路铺轨。具有牵引能力大，机动性能好、工作可靠、调动灵活和对底板适应性好等优点。但其结构复杂、零部件磨损较严重。目前部分断面掘进机通常采用履带式行走机构。两条履带分别由各自的动力来驱动，可实现原地转向。履带的驱动动力有电动机和液压马达两种，电动机驱动一般只设置一种行走速度，液压马达驱动可采用低速大扭矩马达直接带动履带链轮，或采用中速液压马达减速器带动履带链轮的传动方式，它可实现无极调速。 履带结构型式有滑动和滚动两种，当机器调动速度10m/min的中、轻型掘进机，宜采用滑动结构型式；当机器的调动速度10m/min的重型、特重型掘进机，应采用滚动结构型式。 c液压系统。液压系统多采用开式系统多路阀集中控制(直接操纵或遥控操纵)方式。以往国内外多采用齿轮泵，近年来掘进机液压系统采用柱塞泵有增多的趋势。 d电控系统。电控系统包括动力部分、控制部分和检测部分。电控系统必须按照煤矿井下防爆要求设计、制造、检验，必须符合 GB3836-2000标准中的有关规定和要求。为了提高掘进机在作业时的安全性，操作的灵活性 以及机械传动部分的故障诊断及监控功能，从实用角度考虑，装设必要的离机遥控装置、测控压力、温度、液位及关键部位的故障诊断装置。3）总体布置总体布置的内容包括以下几个方面：（1）确定各部件在整机说的位置，并对外形尺寸提出要求；（2）确定各部件、部件与整机之间的连接方式；（3）估算整机重量，并对各部件的重量提出要求；（4）布置各操纵机构、司机座位等；（5）审核个运动部件的运动空间，排除可能发生的运动干涉。4） 具体要求在掘进机总体布置时，需注意以下问题：（1）工作机构减速器减速器的进、出轴尽量同轴线；（2）悬臂和铲板的尺寸关系相适应，既有利于装载，又要避免截割头截割铲板；（3）悬臂的水平和垂直摆动中心的位置可以重合，也可以不重合。从增加机器的稳定性看，摆动这些都高度应尽量降低。在保证悬臂不与其他机构干涉的条件下，摆动中心的位置应尽量靠后，但必须保证中心在机器的纵向对称平面内；（4）操纵台位置要适当，应保证司机操纵方便、省力。仪表显示装置的位置要便于司机观察，又不分散司机正常操作的注意力。5）传动型式及动力元件的选择a传动型式及元件选择应遵循的原则（1）技术先进性：能够改善机器性能，提高生产率；（2）经济合理性：传动系统尽量简单、元件少，易加工，价格低，维修容易，使用寿命长；（3） 工作可靠性:传动系统的可靠性表现为元件使用寿命，因此也是对元件质量的要求；（4） 适应性：元件应适应传动系统的载荷、工况及环境等条件的要求。b各机构对传动系统的要求及传动型式的选择掘进机的截割、装载、运输、行走等机构一般均为分别传动，各部件受力状态及工作条件不同，因而传动型式有不同的要求。（1）工作机构要求有较大的短时过载能力，而油马达对冲击负荷很敏感，过载负荷能力低，影响截割头正常连续运转。所以，掘进机的工作机构宜采用电动机为动力的机械传动型式。应利用体积小、功率大、过负荷能力强的专用电动机，并配备可靠的电气保护装置。根据工作机构结构紧凑的特点，通常工作机构的减速器设在悬臂内，成为悬臂的组成部分。截割头调速方式一般采用配换挂轮的方法，变速机构力求简单。（2）耙装机构传动装置的特点是：减速器需装在尺寸有限的铲板下部，因而设计空间较小，工作条件恶劣。减速器经常浸泡在煤岩泥水中，卡料时易过载。耙装、输送机构若采用齿轮油马达传动，由于尺寸小、重量轻，可使二者分别传动，从而简化传动装置，便于在铲板下布置，便于设计密封效果好的机械密封或将减速器与铲板分离，同时可实现过载自动保护。2确定整机主要技术参数 掘进机整机主要技术参数包括尺寸参数 (长宽高)、重量参数、运动参数和动力参数。 1）尺寸参数整机长度、宽度的大小直接与其转弯半径有关，推荐轻型机长度75m，中型机长度85m，重型机l0m，对应的宽度分别为1.6m，2.5m，3m。 整机的高度直接关系到它的动、静态稳定性，适应范围和通过性的好坏，因此越低越好。当今中外机型发展趋势是矮机型，中、重型机高度 1.62m